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Jumpstart your investment casting process

Save time and money in your investment casting projects by directly printing your foundry patterns. By pairing Somos TetraShell software with our Stereolithography technology, you can eliminate the need for time-consuming and expensive tool production. With 3D-printed foundry patterns, you get a fast, economical and flexible solution for your casting projects. In addition to prototyping, our patterns are also ideal for tool validation and casting small series of metal components.

How Does TetraShell Work?

TetraShell is a process to create an extremely lightweight model in Stereolithography which is used by foundries to make a ceramic shell for metal casting. TetraShell software converts a solid 3D design file into a hollow model consisting of a very thin outer shell and reinforced with a tetrahedron structure inside. The lightweight structure prevents the ceramic shell from being damaged by thermal expansion.

The solid 3D model

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The model is hollowed in TetraShell software to create a pattern

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The pattern is built in Stereolithography

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The pattern is finished

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A ceramic shell is casted around the pattern and the pattern is burned out, leaving a mold

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Liquid metal is poured into the mold, and it then solidifies

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The mold is broken and the part exposed

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The part is ready, without further finishing

The solid 3D model

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The model is hollowed in TetraShell software to create a pattern

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The pattern is built in Stereolithography

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The pattern is finished

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A ceramic shell is casted around the pattern and the pattern is burned out, leaving a mold

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Liquid metal is poured into the mold, and it then solidifies

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The mold is broken and the part exposed

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The part is ready, without further finishing

Why choose TetraShell?

Building investment casting patterns in one piece results in better dimensional accuracy and repeatability, and reduces the risk of surface flaws such as inclusions. Our patented Mammoth Stereolithography machines allow us to build patterns with a length up to 2.1 meters, and with the best surface finish in their class. With a fully-equipped facility for Stereolithography and a dedicated post-production unit, our large capacity allows us to offer you competitive lead times for your 3D-printed patterns.

Ideal applications for TetraShell

Patterns for investment casting or lost wax casting for industries including:

Aerospace and aeronautics

Energy, oil and gas

Architecture

Automotive

Marine engineering

Art and jewelry

Choose TetraShell When You Need…

Complex geometries with the highest design freedom

Very smooth surface finish

High dimensional accuracy and stability (± 0.2%)

Rapid production compared to traditional methods

Large parts up to 2.1 m in length

Lower ash residue than other 3D-printed patterns

Technical Specifications for TetraShell

Standard lead time

Minimum of 5 working days, depending on part size, number of parts and finishing degree

Standard accuracy

± 0.2% (with lower limit on ± 0.2 mm)

Maximum part dimensions

2100 x 700 x 800 mm

Material for TetraShell

This variant of the Tusk2700 material features low moisture absorption and high stability, resulting in accurate casting patterns. TuskXC2700T is a transparent material with a slight blue tinge, and is suitable for a variety of fine finishing degrees. The transparency of this material ensures thorough drainage of residual resin for a better casting quality. TuskXC2700T also results in lower ash residue compared to other 3D-printed patterns, at 0.095%. With these characteristics, TuskXC2700T reduces the risk of surface imperfections.